激光机器人光内送粉异形实体成形研究

为了利用激光熔覆直接成形技术得到异形变截面圆环链轮轮齿模拟件，采用光内送粉技术、利用库卡机器人进行运动控制。根据优化的工艺参量，采用高度额外增量法、长度额外增量法规划扫描路径，精准地控制每层提升量。实验前对基板进行预热，并对成形零件进行检测分析。解决了异形件堆积最容易出现的边缘塌陷问题。在保证变截面结构尺寸各处充分的基础上，较好地控制了加工余量。避免了熔覆层的开裂和剥落，在42CrMoV基板上成功堆积出异形轮齿模拟件。结果表明，光内送粉粉末利用率达60%以上；成形轮齿表面光滑无粘粉，各尺寸误差均在合理范围之内；轮齿与基板冶金结合良好，组织均匀致密，各处硬度均匀。

Laser direct forming research of irregular-section entity base on inside-laser powder feeding and robotic technology

In order to get simulation teeth of ring sprockets with variable cross-section by means of laser cladding direct manu facturing technology , experiments were made based on inside-laser powder feeding technology and motion control of KUKA robot.According to the optimized process parameters , the scanning paths were planed and the lift amount of each layer was accurately controlled based on the incremental method of extra height and extra length .The substrate was preheated and the detection of dimension and microstructure of the formed tooth was made .The problem of edge collapse in the forming of irregular-section parts was solved .The machining allowance was controlled preferably on the basis of promising the sufficient size in different sections .And the cracking and spalling of cladding layer was avoided .The irregular-section tooth was successfully made on 42CrMoV substrate.The results indicate that the powder utilization rate is more than 60% in the processing.The surface of the part was smooth with no powder adhered .The size of the entity was within reasonable limits .The teeth and the substrate formed good metallurgical combination .The microstructure was uniform without microcracks and the microhardness was uniform in every section .